This paper presents the results of preliminary research designed to explore in depth the design, fit and comfort of selected sports bras for large breasted women worn under soft body armour. Female armed personnel need to feel safe and protected in soft armour vests, giving them physiological comfort to perform their duties daily. Troublesome physical and additional physiological problems in relation to the female body are frequently caused due to the poor design of various bra components. Different breast sizes require unique bras designs. Specifically, when it comes to plus-size breasts, all the difficulties of fitting are more evident. In general, retail bra designs are not overcoming the above-mentioned bra's wear problems even before consideration of how they relate to be worn under the soft body armour. As breast size and shape vary greatly between individuals, the design of bra size and style are important. In addition, fit and comfort are the most important factors of concern to the customers. With an aim to achieve a perfect bra shape, fit and comfort, designers have a strong drive to develop a superior quality bra by properly using components and materials with high performance. Five commercial sports bras were selected based on their suitability for wear under body armour. The bras were fitted on a fit model and ranked in terms of the design criteria (1) non-wire, firmness and comfort, (2) fit and size range (D to G-cup) shape, (3) moisture wicking, and (4) composition and textile quality. They were then assessed for correct fit by an expert bra fitter and photographed to assess frontal and side-shape protrusion for mobility and for comfort on the side upper arm. Comparisons indicated differences in the side arm protrusion for some popular brands. Further wear test under a simulation mock-up body armour vest was conducted for observing comfort and moisture management performance over a period of 6 hours. The bra comfort performance was compared.